Senior Electromechanical Engineer

Department: TEC Electrical & Battery

Experience Level: 69 Years

Location: Chennai India

Position Type: Full-Time / New Role

As a Senior Electromechanical Engineer you will own the physical packaging structural housing and mechanical integration of our high-voltage battery modules and electrical powertrain systems into the eVTOL airframe. This is a highly cross-functional role bridging electrical power architectures and structural mechanics. You will transform complex electrical systems into flight-ready structural assemblies ensuring optimal thermal paths structural integrity under high-g flight envelopes and strict optimization for aircraft weight and mass balance.

• Enclosure & Packaging Design: Design robust lightweight and crash-worthy enclosures mounts and structural brackets for high-voltage battery packs power electronics power distribution units (PDUs) and inverter modules.
  

• Advanced 3D Modeling: Utilize CATIA V5/V6 (3DEXPERIENCE) to build complex electromechanical assemblies leveraging surface modeling for aerodynamic integration and airframe routing constraints.
  

• Precision Engineering & GD&T: Apply rigorous Geometric Dimensioning & Tolerancing (GD&T) principles per ASME Y14.5 to ensure flawless fitments between machined enclosures sheet metal shields and composite airframe interfaces. Perform detailed tolerance stack-up analyses.
  

• Design for Excellence (DfM / DfA / DfT): Inject Design for Manufacturing Assembly and Testing principles early into the development lifecycle to drive down component counts minimize assembly cycle times and simplify shop-floor production.
  

• Material & Structural Selection: Select and qualify aerospace-grade alloys high-performance plastics structural adhesives and advanced Thermal Interface Materials (TIMs) to maximize heat dissipation while ensuring structural safety.
  

• HV Isolation Engineering: Coordinate closely with the electrical team to design mechanical clearances that respect strict creepage and clearance boundaries for high-voltage components.
  

• HV Box Design: Assemblies involving Contactors Busbars Fuses Pyrofuses Manual Service Disconnect switches etc.
  

• Experience : 6 to 9 years of dedicated mechanical or electromechanical packaging experience within the aerospace electric vehicle (powertrain/battery) or high-reliability defense sectors.
  

• CAD Mastery : Advanced hands-on expertise in CATIA V5 / V6 (3DEXPERIENCE) specifically utilizing advanced assembly design sheet metal workbenches and mechanical part design.
  

• Drafting & Stack-up Depth : Expert-level knowledge of GD&T and a proven track record of resolving complex multi-part tolerance stack-ups.
  

• Manufacturing Knowledge : Direct experience designing parts optimized for CNC machining sheet metal fabrication structural bonding and lightweight casting or molding.
  

• Exposure to Electrical System Design constraints : Excellent understanding & design capability on - Ingress protections Water proof / Dust proof designs Good understanding of clearance & creepage distances Switches Panel creation Electrical sub-assemblies.
  

• Certification / Compliance : Experience in prototyping as well as production planning kind of environment. Ideal candidates should have designed developed & taken at least one such development through full certification through the likes of DGCA / CEMILAC / ARAI.
  

• Working knowledge of Mechanical Shape Design within CATIA for complex surface modeling.
  

• Experience packaging high-voltage systems (upto 800VDC) and managing mechanical safety barriers against electric shock or thermal runaway.
  

• Familiarity with environmental testing standards like RTCA DO-160 (specifically regarding vibration shock and thermal profiles).
  

• Excellent understanding of electrical system design electrical properties of materials dielectric strength creepage & clearances thermal properties of materials.
  

• Good understanding of - Grounding / bonding required for electrical components Enclosure design & fabrication for electrical systems Design for Ingress Protections.
  

• Exposure to material selection for electrical products.